ATSG Ford 4R100 Service Manual

FORD 4R100

INDEX

IDENTIFICATION TAG LOCATION AND INFORMATION ............................................................... 3

GENERAL DESCRIPTION AND OPERATION ..................................................................................... 4

COMPONENT AND SOLENOID APPLICATION CHART ................................................................... 5

"PTO" GENERAL REQUIREMENTS .................................................................................................... 6

ELECTRICAL COMPONENT DIAGNOSIS ........................................................................................... 8

FLUID REQUIREMENTS ....................................................................................................................... 12

SOLENOID PACK TESTING .................................................................................................................. 12

ABBREVIATION DESCRIPTION .......................................................................................................... 14

DIAGNOSTIC TROUBLE CODE CHART AND DESCRIPTION ........................................................ 15

LINE PRESSURE TEST .......................................................................................................................... 21

NON-PTO AND PTO HYDRAULIC DIFFERENCES ........................................................................... 22

PWM AND NON-PWM OIL PUMP DIFFERENCES ........................................................................... 34

CASE CHECKBALL LOCATIONS ......................................................................................................... 38

VALVE BODY CHECKBALL LOCATIONS ........................................................................................... 39

AIR PRESSURE CHECKS ...................................................................................................................... 40

TRANSMISSION DISASSEMBLY ......................................................................................................... 41

COMPONENT REBUILD SECTION

TRANSMISSION CASE ASSEMBLY ................................................................................................ 55

FRONT AND REAR PLANETARY CARRIERS ............................................................................... 64

FORWARD CLUTCH HOUSING ...................................................................................................... 66

DIRECT CLUTCH HOUSING ........................................................................................................... 69

FORWARD, DIRECT, SUN SHELL SUB-ASSEMBLY .................................................................... 76

CENTER SUPPORT ASSEMBLY ...................................................................................................... 80

INTERMEDIATE/OVERDRIVE CYLINDER ASSEMBLY ............................................................. 82

OVERDRIVE GEARSET ASSEMBLY ............................................................................................... 84

COAST CLUTCH HOUSING DIFFERENCES ................................................................................ 88

COAST CLUTCH HOUSING ASSEMBLY ........................................................................................ 90

OIL PUMP ASSEMBLY ...................................................................................................................... 94

VALVE BODY ASSEMBLY ............................................................................................................... 100

TRANSMISSION FINAL ASSEMBLY ................................................................................................. 102

MANUAL VALVE CHECK .................................................................................................................... 111

MANUAL SHIFT LEVER DIFFERENCES ........................................................................................ 112

TORQUE SPECIFICATIONS ............................................................................................................... 115

VALVE BODY BOLT CHART AND IDENTIFICATION .................................................................... 116

BOLT CHART AND IDENTIFICATION ............................................................................................. 117

SPECIAL SERVICE TOOLS ................................................................................................................. 118

AUTOMATIC TRANSMISSION SERVICE GROUP

18639 S.W. 107TH AVENUE

MIAMI, FLORIDA 33157

[phone]

Copyright © ATSG 2003

INTRODUCTION

Updated

October, 2003

FORD 4R100

The Ford 4R100 transmission is an updated version of the E4OD and was first introduced in the 1999 model
year, and is currently found in the F250, F350, F450 and F550 Super Duty trucks, E150, E250, E350, E450 vans
and the Expedition/Navigator/Excursion vehicles equipped with the 5.4L, 6.8L, and 7.3L engines. Some of the
4R100 units are equipped with a Power-T ake-Off (PT O) window on the left hand side of the transmission case.
The revisions in the 4R100 have created many new engineering changes that have affected many of the internal
and external parts that will affect the servicing, repairing and overhaul of these units.

We wish to thank Ford Motor Company

for the information and illustrations
that have made this booklet possible.

No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or
by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise,
without written permission of Automatic Transmission Service Group. This includes all text illustrations,
tables and charts.

The information and part numbers contained in this booklet have

been carefully compiled from industry sources known for their

reliability, but ATSG does not guarantee its accuracy.

DALE ENGLAND

FIELD SERVICE CONSULTANT

WAYNE COLONNA

TECHNICAL SUPERVISOR

PETER LUBAN

TECHNICAL CONSULTANT

JON GLATSTEIN

TECHNICAL CONSULTANT

ROLAND ALVAREZ

TECHNICAL CONSULTANT

GERALD CAMPBELL

TECHNICAL CONSULTANT

Copyright © ATSG 2003

JIM DIAL

TECHNICAL CONSULTANT

ED KRUSE

TECHNICAL CONSULTANT

GREGORY LIPNICK

TECHNICAL CONSULTANT

DAVID CHALKER

TECHNICAL CONSULTANT

JERRY GOTT

TECHNICAL CONSULTANT

MIKE SOUZA

TECHNICAL CONSULTANT

AUTOMATIC TRANSMISSION SERVICE GROUP

18639 S.W. 107TH AVENUE

MIAMI, FLORIDA 33157

[phone]

1

Technical Service Information

TRANSMISSION IDENTIFICATION

WITH POWER TAKE OFF OPTION

Note:

PTO is available as an option on 8500 GVW or above, Super Duty
F-Series trucks with 6.8L gasoline and 7.3L Diesel e ngines.
Ford 4R100 transmissions on other models are not PTO capable.

Ford

Ford

RFF81P-7006-BA

98

AC

-

P

4

W

X

-B

L

J

R

1

6

3

04

0

7

1

C

D-9

B

55GG

0043616520

Assembly Part Number, Prefix And Suffix1
Transmission Model

2

Serial Number

3

XW4P-AC
RJL-B
004361
BD-9C17

4 X 44 X 4

Fo

r

d

Year Month Day

17C9BD-

1

Build

Date

2
3
4

9=1999
0=2000
1=2001
2=2002
3=2003

A=Jan
B=Feb
C=Mar
D=Apr
E=May
F=Jun
G=Jul
H=Aug
J=Sep
K=Oct
L=Nov
M=Dec

Build Date (Year, Month, Day)

4

AUTOMATIC TRANSMISSION SERVICE GROUP

Copyright © 2003 ATSG

Figure 1

3

Technical Service Information

TRANSMISSION

DESCRIPTION AND OPERATION

General Description

The Ford 4R100 automatic transmission is a four
forward speed unit with electronic shift control. It is
designed for longitudinal powertrains for rear wheel
drive vehicles.
The 4R100 transmission features a four element
torque converter design that includes Torque
Converter Clutch (TCC) and a gear train that includes
three planetary gearsets.
Some models provide for Power Take Off (PTO)
operation in all transmission shift lever positions.
During PTO operation in OD, 4th gear is disabled.
The hydraulic control system of the 4R100 unit has
five electronically controlled solenoids for:
Shift feel, through line pressure control.
Shift scheduling, through shift valve position.
Engine braking during coast conditions.
TCC apply (On/Off or Modulating).

Major Internal Components

"Seven Friction Apply Elements"
Intermediate Band

Coast Clutch, Multi-disc
Overdrive Clutch, Multi-disc
Intermediate Clutch, Multi-disc
Direct Clutch, Multi-disc
Forward Clutch, Multi-disc
Low/Reverse Clutch, Multi-disc

"Three One-Way Clutches"
Overdrive Roller Clutch

Intermediate Sprag
Low Roller Clutch

Shift Quadrant Indicator

V ehicles equipped with the 4R100 transmission have
a Transmission Control Switch (TCS), also referred to
as "Overdrive Cancel Switch", and a Transmission
Control Indicator Lamp (TCIL), located on the end of
the manual gear shift lever, as shown in Figure 3. The
TCS is a momentary contact switch. When this
switch is pressed, a signal is sent to the PCM to allow
automatic shifts from 1st to 4th gear or from 1st to 3rd
gear. After the TCS has been pressed the PCM turns
on the TCIL lamp ("OFF"), to indicate that overdrive
has been canceled, as shown in Figure 3.

The shift quadrant has the following positions, as
shown in Figure 2: P , R, N, D , 2 and 1.

D position (TCS OFF) provides 1-2-3-4 automatic
upshifts and downshifts. Coast braking occurs in 4th
gear. (TCIL Not Illuminated)

D position (TCS ON) provides 1-2-3 automatic
upshifts and downshifts. Coast braking occurs in 3rd
gear. (TCIL Illuminated)

2 position provides a pull-in shift to 3rd gear with
coast braking. After an automatic downshift, a 2nd
gear hold occurs with coast braking.

1 position provides a pull-in shift to 2nd gear with
coast braking. After an automatic downshift, a 1st
gear hold occurs with coast braking.

"Three Simple Planetary Gearsets"
Overdrive

Forward
Reverse

"Typical" Shift Quadrant Indicator

P R N

Figure 2 Figure 3

4

D

2 1

Copyright © 2003 ATSG

OVERDRIVE OFFOVERDRIVE OFF

AUTOMATIC TRANSMISSION SERVICE GROUP

TCS

SWITCH

TCIL LAMP

Technical Service Information

Overdrive

Clutch

FORD MOTOR COMPANY

4R100 ("PTO" Version Illustrated)

Intermediate

Clutch

Low/Reverse

Clutch

GEAR

Park/Neut

Overdrive

Roller Clutch

Fwd
Clut

Int

Clut

Coast

Clutch

Intermediate

Sprag

Direct

Clutch

Intermediate

Forward

Clutch

Low

Roller Clutch

Band

COMPONENT AND SOLENOID APPLICATION CHART

Dir

Clut

O.D.

Clut

Cst

Clut

Int

Band

L/R

Clut

O.D.

Roller

Int

Sprag

Low

Roller

SS1 SS2

On

GEAR RATIOS

Reverse - 2.18

1st Gear - 2.71

2nd Gear - 1.54

3rd Gear - 1.00
4th Gear - 0.71

SOLENOIDS

CCS

TCC EPC

Off Off

Off

Mod

Reverse
OD-1st
OD-2nd
OD-3rd
OD-4th
OD-3rd**
M-2nd
M-1st

ON ON
ON Hold
ON ON

ON

ON
ON
ON
ON
ON

ON
ON
ON

ON

ON ON

ON

ON
ON ON
ON

ON

ON

Hold

Hold Hold
Hold

Hold
Hold
Hold

Hold

Hold

Hold

On

Off Off Off
On *On
OnOnOn
Off
Off
Off

On

*Off

Off

*Off

On

*Off

Off

Off

On On

On

On

Off

*On
*On
*On
*On
*On

Off

OD-3rd** = TCS "On" with TCIL illuminated showing "Off"

*On = If the PCM determines that powertrain operating conditions exist for TCC apply, the TCC solenoid may
be On (Modulating with PWM TCC units) in any forward gear except Manual 1st.

*Off = Will be "On", if the TCS switch is pushed.
Mod = Modulating at all times by the PCM and line pressure will be regulated based on throttle position,

engine load and vehicle speed.

Copyright © 2003 ATSG

Figure 4

AUTOMATIC TRANSMISSION SERVICE GROUP

Mod
Mod
Mod
Mod
Mod
Mod
Mod
ModOn

5

Technical Service Information

PTO "GENERAL" REQUIREMENTS:

(1)

Obviously the case must be PTO capable with
the cast-in window in the transmission where the
PTO unit mounts to the transmission, as shown in
Figure 5.

(2)

Designed for use during Mobile (Some Models)
or Stationary conditions.

(3)

PTO is available as an option only on 8500 GVW
or above, Super Duty F-Series trucks with 6.8L
Gasoline and 7.3L Diesel engines. Ford 4R100
transmissions on other models are not PTO
capable.

(4)

Battery voltage must be supplied to the
Powertrain Control Module (PCM) input pin 4
on gasoline models, or pin 66 on diesel models,
when the PTO is engaged. The processor uses
this information to raise EPC pressure to
approximately 55 PSI so that you do not burn the
coast clutch. This voltage must be provided by

the PTO installer .

(5)

Shift Solenoid 2 and the Coast Clutch Solenoid
must be energized when the PTO is turned ON.

PTO

Window

dF

d

or

or

F

006-BA

RFF81P-7

98

Fo

rd

Copyright © 2003 ATSG

Figure 5

TRANSMISSION FUNCTIONS

DURING PTO OPERATION:

(1)

Shift Solenoid 2 and Coast Clutch Solenoids are
turned on, the coast clutch activates and does not
allow 4th gear operation during PTO operation.

C

A

-

P

4

W

X

B

-

L

RJ

1

6

3

04

0

7

1

C

9

-

D

B

"GENERAL" CONDITIONS FOR OPERATION

(1)

The vehicle is not in the crank or start mode.

(2)

The transmission range selector must be in the P,
R, O.D, 2 or 1 position. The PTO will not operate
when selector is in the neutral position.

(3)

PTO operation is inhibited when in cranking
mode, neutral, or 4th gear.

(4)

Transmission only operates 1st through 3rd
gears. Computer strategy does not allow 4th
gear to engage, under any conditions.

(5)

Transmission Fluid Temperature Sensor (TFT)
reading must be up to operating temperature.

GASOLINE ENGINE PTO OPERATION:

(1)

PTO installer must obtain a "High Idle Throttle
Control" from an aftermarket source.

(2)

Auxiliary Powertrain Control Module seen on
Page seven, does not work on the gasoline engine
models. APCM module works only on the 7.3L
diesel engine.

(3)

For stationary PTO operation an engine idle
speed of 1300 RPM is required.

(2)

Electronic Pressure Control (EPC) pressure is
raised to approximately 55 PSI. This is why the
coast clutch will be smoked in a short period of
time if a battery voltage wire is not supplied to
EEC input pin 4 (gasoline) or pin 66 (diesel)
when the PTO is engaged, as this rise in pressure
would not occur.

(3)

The Transmission Control Indicator Lamp
(TCIL) illuminates.

(4)

When the PTO is turned ON, the transmission
operates only in 1st through 3rd gears.
Overdrive 4th gear is not allowed by the PCM
strategy.

(5)

The transmission shift schedule is early and shift
feel is very firm.

(6)

PTO operation can cause transmission fluid
temperature to exceed the recommended
maximum limit of 250 degrees F. Failure mode
logic within PCM strategy prevents transmission
damage by disabling the PTO above this
temperature limit.

(4)

The Torque Converter Clutch (TCC) engages

Specific Operation For Diesel, See Page 7.

once the engine reaches 1300 RPM.

6

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

DIESEL ENGINE PTO OPERATION:

"AUXILIARY" POWERTRAIN CONTROL MODULE

7.3L DIESEL ENGINE (ONLY)

The Auxiliary Powertrain Control Module (APCM) commands the Electronic Engine Control
(EEC) module to increase the idle speed during PTO operation. The APCM controls engine
speed from 1300 to 2500 RPM.

The Auxiliary Powertrain Control Module is a seperate option, it does not come standard with a
PTO capable transmission, and is for 7.3L diesel applications only .

Intended for stationary use only, and in stationary operation the PT O requires an engine idle speed
of 1300 RPM. During stationary PTO operation on the 7.3L diesel, the EEC increases the idle to
1300 RPM automatically.

During stationary PTO operation, the Torque Converter Clutch (TCC) engages once the RPM
reaches 1200-1300 RPM.

The following conditions must be met before the idle speed is increased:

1. Parking brake must be engaged for all applications.

2. No hydraulic brake actuation.

3. Accelerator pedal must be in the idle position.

4. V ehicle speed must be zero MPH.

5. Brake lights must be functional.

FordFord

CHARGE PROTECTION APPLICATION

Charge Protection is used for maintaining battery charge.
In Charge Protection mode, the battery voltage is monitored and the
engine idle speed is increased as necessary, so the battery charge is
maintained as required.
Charge Protection can be activated from in-cab and can be
programmed to activate automatically on engine start-up.

RPM CONTROL

RPM Control is used for

RPM Control mode can be
activated from in-cab and
can be programmed to
activate automatically on
engine start-up.
The programmable speed
presets range from 1300 to

This is the recommended
method of elevating idle
speed for PTO operations.

AUXILIARY POWERTRAIN CONTROL MODULEAUXILIARY POWERTRAIN CONTROL MODULE

Exclusively for light trucks with the 7.3L Diesel Engine.
Intended for Stationary Use Only.
Order Guide Option Code 961.

RPM

RPM

CHARGE

CONTROL

CONTROL

CHARGE

PROTECT

PROTECT

POWERPOWER

FordFord

2500

KITS INCLUDE

Aux. Powertrain Control Module.
Mounting Hardware and Bracket.
Wiring Harness.
Instruction Booklet.
Operators Card.

LCD screen displays the current
engine speed or battery voltage.

Each Single Arrow key contains a
preset speed allowing for four
programmable RPM settings.

The Double Arrow keys can also be
used to manually raise or lower the
engine speed at a faster or slower
rate.

Figure 6

AUTOMATIC TRANSMISSION SERVICE GROUP

Copyright © 2003 ATSG

7

Technical Service Information

DIAGNOSTIC CONCERNS WITH PTO
EQUIPPED VEHICLES:

(1)

Always ensure that PTO is turned OFF, before
any diagnostic procedures begin.

(2)

Never perform any transmission special tests
(i.e. pressure test, stall test etc.) when the PTO is
turned ON.

(3)

If a transmission concern or symptom goes
away with the PTO turned OFF , it is most likely

not a transmission concern.

(4)

On Board Diagnostics operate normally during
PTO operation with the exception of the engine
misfire monitor. The circuit checks made by the
PCM and Failure Mode Effect Management
(FMEM) capability will continue. The PTO
must be turned OFF to access Diagnostic
Trouble Codes (DTC's) and perform OBD tests.

Caution: If the batteries are disconnected for any
reason, the PCM "must" have a 7 mile drive cycle at
speeds above 50 MPH, before it remembers that it is
capable of running a PTO

CENTRAL JUNCTION BOX

FUSE 19

Red/Yellow

ELECTRICAL COMPONENT DIAGNOSIS

Accelerator Pedal Position Sensor (Diesel Only)

The Accelerator Pedal (AP) position sensor is
mounted on the accelerator pedal inside the vehicle
and detects the position of the accelerator pedal and
sends this information as a varying voltage signal to
the PCM. The PCM then uses the monitored voltage
level of the AP sensor for control of EPC pressure and
shift scheduling.
The Idle Validation Switch is fed voltage through
fuse number 19, as well as the Transmission Control
Switch, as shown in Figure 7.

If the Idle Validation Switch feed voltage is lost for
any reason, the engine will immediately return to
idle and stay there until feed voltage is restored.

4X4 Low Switch

The 4X4 Low Switch is used to the PCM that the
transfer case system is operating in LOW range. The
PCM receives the 4X4 Low Switch input signal and
modifies shift scheduling for the lower gear ratio
(See Figure 8).
If the 4X4 LOW indicator fuse is blown, the
transmission will shift according to the 4X4 LOW
shift schedule, regardless of transfer case lever

position.

Transmission Control Switch (TCS)
Clutch Pedal Position (CPP) (Std Trans Only)

Idle Validation Switch (IVS) (Diesel Only)
Overhead Trip Computer Module
Generic Electronic Module (GEM)
Instrument Cluster Terminal A12
Instrument Cluster Terminal B11

Copyright © 2003 ATSG

Figure 7

PCM PIN 14

Lt. Blue/Black

Figure 8

8

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Turbine Shaft Speed Sensor Output Shaft Speed Sensor

The Turbine Shaft Speed (TSS) sensor is a magnetic
pickup that sends the PCM a frequency signal related
to the rotating speed of the transmission input shaft.
The TSS mounts on the top front of the case on some
models, as shown in Figure 9. W e have also provided
you with the resistance readings and OEM part
numbers on both Turbine Speed Sensors, as the PTO
and Non-PTO models use different sensors, as shown
in Figure 9.
The PCM uses the TSS sensor signal to control EPC
pressure and TCC strategy .

Turbine Shaft Speed Sensor

PTO Models Only = 496-1244 Ohms Resistance

Part Number F81Z-7M101-BA

Non PTO Models Only = 781-1979 Ohms Resistance

Part Number F81Z-7M101-AA

The Output Shaft Speed (OSS) sensor is a magnetic
pickup that sends the PCM a frequency signal related
to the rotating speed of the transmission output shaft.
The OSS sensor was added to the top of extension
housing, as shown in Figure 10. The OSS is triggered
by an added rotor pressed onto the output shaft. The
park gear is also now pressed onto the output shaft,
and the number 13 thrust washer has changed to a
thrust bearing, as shown in Figure 11. We have
provided you with the resistance reading and the
OEM part number for the output shaft speed sensor.
Refer to Figure 10 for output shaft speed sensor
information.
The PCM uses the OSS sensor signal to control EPC
pressure, shift scheduling and TCC strategy .

Copyright © 2003 ATSG

Figure 9

Output Shaft Speed Sensor

All Models = 781-1979 Ohms Resistance

Part Number F81Z-7M101-AA

The Park Gear is also a press fit to the output
shaft, and the number 13 thrust washer, between
the case and the park gear has been replaced
with a needle bearing.

OSS Rotor Park Gear

(Press Fit)(Press Fit)

Copyright © 2003 ATSG

Copyright © 2003 ATSG

Figure 10 Figure 11

AUTOMATIC TRANSMISSION SERVICE GROUP

9

Technical Service Information

ELECTRICAL COMPONENT DIAGNOSIS

Digital Transmission Range Sensor

The Digital Transmission Range (DTR) sensor has a
twelve pin electrical connector and is located on the
outside of the transmission at the manual lever, as
shown in Figure 12.
The DTR sensor completes the start circuit in Park
and Neutral, the backup lamp circuit in Reverse, and
the neutral sense circuit (4WD Only) when in Neutral.
The DTR sensor also opens or closes a set of four
different switches that are monitored by the
Powertrain Control Module (PCM) to determine the
position of the transmission manual lever. Refer to
Figure 13.

DTR TESTING PROCEDURE

In Figure 13 we have provided you with pin number
identification for both the transmission range sensor
and the vehicle harness. We have also provided a
chart that will give you the open/closed state of each
internal switch, dependent on selector position, and

notice that three positions read a 270W resistor, that is
also internal.

Note: All testing that we have provided for you is
done with a DVOM, set to the ohms position, and all
tests are performed with the ignition switch in the
"OFF" position.

(1)

Testing the transmission range 3A switch, and
the 270W internal resistor is done across pins 2

and 3 of the DTR sensor, and must be checked in
each selector position to determine the switch
and resistor integrity. Refer to Figure 13.

(2)

Testing the transmission range 1 switch is done
across pins 2 and 4 of the DTR sensor, and must
be checked in each selector position to
determine switch integrity. Refer to Figure 13.

(3)

Testing the transmission range 2 switch is done
across pins 2 and 5 of the DTR sensor, and must
be checked in each selector position to
determine switch integrity. Refer to Figure 13.

(4)

Testing the transmission range 4 switch is done

C

A

-

P

4

W

X

-B

RFF81P-7

ordFord

F

006-BA

98

L

J

R

1

6

3

4

0

0

7

1

C

9

-

D

B

across pins 2 and 6 of the DTR sensor, and must
be checked in each selector position to
determine switch integrity. Refer to Figure 13.

F

or

d

(5)

Testing the reverse lamp circuit is done across
pins 9 and 11 of the DTR sensor, and must be
checked in each selector position to determine
switch integrity. Refer to Figure 13.

(6)

Testing the neutral start circuit is done across
pins 10 and 12 of the DTR sensor, and must be
checked in each selector position to determine
switch integrity. Refer to Figure 13.

NEUTRAL

L

C

AA

­293

-7F
TP

F7

Ford

10

Copyright © 2003 ATSG

Figure 12

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

126
115
104

1 7

23456 1

12 11 10 9 8

7

93
82

View looking into DTR Sensor

Pin No.

1
2
3
4
5
6

Not Used Ground
Signal Return (Ground)
TR3A (5 Volts from PCM)
TR1 (10-12 Volts from PCM)
TR2 (10-12 Volts from PCM)
TR4 (10-12 Volts from PCM)

P R N 2 1TERMINALS

2 AND 3 CLOSED
2 AND 4
2 AND 5
2 AND 6

CLOSED CLOSED CLOSED
CLOSED
CLOSED

CLOSED

OPEN

Pin No.Function

10
11
12

OPEN

View looking into DTR Sensor

harness connector-terminal side

Function

7
8
9

Neutral
Battery Voltage Feed
Fuse 21, Hot In Start
Back-up Lamps
Starter Relay

D

270 W270 W270 W

OPEN OPEN

OPEN

CLOSED

CLOSED

OPEN

CLOSED

OPEN
OPENOPEN

CLOSEDCLOSED

9 AND 11

10 AND 12

OPEN OPEN

CLOSED

CLOSED

OPEN

CLOSED

9 11 12 10 4 5 6 32

P

N

1

P

2R

D

N

1

P

2R

D

N

1

P

2R

D

DIGITAL TRANSMISSION RANGE SENSOR

Figure 13

AUTOMATIC TRANSMISSION SERVICE GROUP

N

OPEN
OPEN

2R

D

OPEN
OPEN

1

P

N

2R

D

OPEN
OPEN

1

P

N

Copyright © 2003 ATSG

1

2R

D

270 W

11

Technical Service Information

ELECTRICAL COMPONENT DIAGNOSIS

Solenoid Assembly

The Solenoid Assembly is bolted to the case and
located inside the bottom pan. The Solenoid
Assembly contains shift solenoid 1, shift solenoid 2,
coast clutch solenoid, TCC solenoid, EPC solenoid
and the TFT sensor. The solenoids are not serviced
individually. Y ou must replace the entire assembly, as
shown in Figure 14. Some of these units are equipped
with an ON/OFF TCC solenoid and some are
equipped with a PWM TCC solenoid, so it is
important to determine which you have.

SOLENOID PACK ASSEMBLY

SOLENOID PACK TESTING PROCEDURE

In Figure 16 we have provided you with pin number
identification for both the transmission case
connector and the vehicle harness. We have also
provided a chart that will give you the function of
each and the ohms readings you should see on each of
the solenoids and the TFT sensor .

Note: All testing that we have provided for you is
done with a DVOM, set to the ohms position, and all
tests are performed with the ignition switch in the
"OFF" position.

(1)

Shift Solenoid 1 is tested across pins 1 and 3,
and should read 20-30 ohms resistance. Refer
to Figure 16.

(2)

Shift Solenoid 2 is tested across pins 1 and 2,
and should read 20-30 ohms resistance. Refer
to Figure 16.

(3)

TCC On/Off Solenoid is tested across pins 1 and
4, and should read 20-30 ohms resistance.
Refer to Figure 16.

Copyright © 2003 ATSG

Figure 14

Transmission Fluid Temperature

°C °F Resistance

-40 to -20

-19 to -1
0 - 20
21-40
41-70
71-90

91-110

111-130

131-150 267-302

-40 to -4

-3 to 31
32-68

69-104
105-158
159-194
195-230
231-266

1062k - 284k W

284k - 100k W

100k - 37k W

37k - 16k W

16k - 5k W

5k - 2.7k W

2.7k - 1.5k W

1.5k - 0.8k W

0.8k - 0.54k W

(4)

TCC PWM Solenoid is tested across pins 1 and
4, and should read 10-20 ohms resistance.
Refer to Figure 16.

(5)

Coast Clutch Solenoid is tested across pins 1
and 5, and should read 20-30 ohms resistance.
Refer to Figure 16.

(6)

EPC Solenoid is tested across pins 11 and 12,
and should read 3.0-5.0 ohms resistance. Refer
to Figure 16.

(7)

TFT sensor is tested across pins 7 and 8. Refer
to the chart provided in Figure 15.

4R100 FLUID REQUIREMENTS

Only Motorcraft Mercon® multi-purpose automatic
transmission fluid XT-2-QDX or an equivalent
Mercon® fluid should be used in all Ford 4R100
transmissions. Before adding any fluid, ensure that it
is the correct type.

Checking Fluid

Always use the transmission fluid level indicator
(Dipstick) to set the correct fluid level. Set the fluid
level at normal operating temperature which is 150°
to 170°F, engine at idle in Park.

12

Figure 15

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

SOLENOID BODY PIN IDENTIFICATION AND FUNCTION

SOLENOID BODY

CONNECTOR

121187

16 2345

VEHICLE HARNESS

CONNECTOR

12 7

1

6

Solenoid Resistance Chart

Solenoid Body

Solenoid

Shift Solenoid "B" (2) 1 and 2 20-30 Ohms
Shift Solenoid "A" (1)
TCC Solenoid, (On-Off)

Pin Numbers

1 and 3
1 and 4

Resistance

20-30 Ohms

20-30 Ohms
TCC Solenoid, (PWM)
Coast Clutch Solenoid
Electronic Pressure Control Solenoid
Transmission Fluid Temp Sensor

Solenoid Connector Pin Identification and Function

DescriptionPin No.

1

Vehicle Power In For Solenoids (VPWR)

2

Shift Solenoid "B" (2) Ground from PCM

3

Shift Solenoid "A" (1) Ground from PCM

4

Converter Clutch Solenoid Ground from PCM

5

Coast Clutch Solenoid Ground from PCM

6

Not Used

7

Transmission Fluid Temp Sensor

8

Transmission Fluid Temp Sensor (Signal Return)

9

Not Used

1 and 4
1 and 5

11 and 12

7 and 8

10-20 Ohms

20-30 Ohms

3.0-5.0 Ohms

See Chart Below

PCM Connector Pin

Gas & Diesel (Cal) Diesel (49 State)

71, 97

11

6
54
20

37
91

71, 97

1
27
28
53

37
91

10

11

12

Not Used
Electronic Pressure Control (EPC)
Vehicle Power In For EPC Solenoid (VPWR)

Figure 16

AUTOMATIC TRANSMISSION SERVICE GROUP

81

71, 97

81

71, 97

13

Technical Service Information

FORD 4R100

Abbreviation Description

Abbreviation AbbreviationDescription Description

4X4L

ABS

A/C

ACCS

AP

APGND

ARPMDES

BARO

BOO

BPA

BPP

BUS +

BUS -

CASE GND

CCS

CID

CMP

4X4 Low Switch
Antilock Brake System
Air Conditioning
Air Conditioning Clutch Status
Accelerator Pedal Position Sensor

Accelerator Pedal Sensor Ground

Ancillary Engine Speed Desired

Barometric Pressure Sensor
Brake ON/OFF Switch
Brake Pressure Applied

Brake Pedal Position
Data Link Connector
Data Link Connector

Case Ground

Coast Clutch Solenoid

Cylinder Identification

Camshaft Position Sensor

ICP
IPR
IVS

KAM

KAPWR

KOEO
KOER

MAF
MAP

MIL

OCT ADJ

OSS
PBA

PCM

PIP
ROM
RPM

Injector Control Pressure Sensor
Injector Pressure Regulator
Idle Validation Switch
Keep Alive Memory
Keep Alive Power
Key On Engine Off
Key On Engine Running
Mass Air Flow Sensor
Manifold Absolute Pressure Sensor
Malfunction Indicator Lamp
Octane Adjust
Output Shaft Speed Sensor
Parking Brake Applied
Powertrain Control Module
Profile Ignition Pickup
Read Only Memory
Engine Speed

CPP

CRUISE

DLC
DTC

DTC CNT

DTR
EBP
ECT
EOT
EPC
EPR

FEPS

FUEL PW

GP
GPC
GPL

IAT

Clutch Pedal Position
Cruise Control Mode (Driving)
Data Link Connector
Diagnostic Trouble Code

Diagnostic Trouble Code Count

Digital Transmission Range Sensor
Exhaust Back Pressure

Engine Coolant Temperature
Engine Oil Temperature

Electronic Pressure Control

Exhaust Pressure Regulator
Flash EPROM Power Supply
Fuel Pulse Width

Glow Plug
Glow Plug Control Duty Cycle

Glow Plug Lamp

Intake Air Temperatur e

SCCS

SS1

SS2
SSA
SSB

SPOUT

TAC

TCC

TCIL

TCS
TFT

TP

TSS

VPWR

VREF

VSS

WOT

Speed Control Command Switch
Shift Solenoid "1"
Shift Solenoid "2"
Shift Solenoid "A"
Shift Solenoid "B"
Spark Output
Tachometer Signal
Torque Converter Clutch
Trans Control Indicator Lamp
Transmission Control Switch
Transmission Fluid Temperature
Throttle Position Sensor
Turbine Shaft Speed Sensor
Vehicle Power Supply
Vehicle Reference Voltage
Vehicle Speed Sensor
Wide Open Throttle

14

Figure 17

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

FORD 4R100

Diagnostic Trouble Code Chart

Diagnostic Code Description Symptom

P0102
P0103

P0107
P0108

P0122

MAF sensor system fails to operate in a
normal manner, which may cause a
transmission concern.
BARO sensor circuit signal higher or lower
than expected.

(TP) Throttle Position sensor or (AP)
Accelerator Pedal Position sensor below
specification during normal operation.

High EPC pressure. Firm shifts
and engagements. May flash TCIL.

Firm shift feel, late shifts at higher
altitudes.

Harsh engagements, firm shift feel,
abnormal shift schedule, abnormal
TCC operation or does not engage.

P0123

P0235

P0236

P0237

P0340
P0341
P0344

P0500
P0503

P0571

(TP) Throttle Position sensor or (AP)
Accelerator Pedal Position sensor above or
below normal specifications during normal
operation.

MAP sensor or circuit open, shorted to ground
or to 5V .

MAP sensor signal higher or lower than
expected or no response due to vacuum hose
circuit damaged, disconnected or restricted.

MAP sensor out of On-Board Diagnostics
range. No response during Dynamic
Response (Goose) test.

(DI) Distributor Ignition circuit concern or
(CKP) Crankshaft Position sensor failure.

Insufficient or intermittent vehicle speed
input from VSS/ABS.

(BPP) Brake Pedal Position switch failure, or
not connected.

Harsh engagements, firm shift feel,
abnormal shift schedule, abnormal
TCC operation or does not engage.

Firm shift feel, late shifts at higher
altitudes.

Firm shift feel, late shifts at higher
altitudes.

Rerun On-Board Diagnostics and
perform "Goose" test when asked.

Engine will stall or will not run.
May flash TCIL.

Harsh engagements, firm shift feel,
abnormal shift pattern, unexpected
downshifts may occur at closed
throttle, abnormal TCC operation or
engages only at WOT. May flash
TCIL.

Failed off. TCC will not disengage
when brake is applied.

P0703

P0705

P0708

P0712

(BPP) Brake Pedal Position switch failure, or
not connected.

(DTR) Digital Transmission Range sensor
circuit malfunction.

(DTR) Digital Transmission Range sensor
circuit malfunction.

TFT sensor circuit grounded, exceeds scale set
for temperature of 315°F .

Figure 18

AUTOMATIC TRANSMISSION SERVICE GROUP

Failed off. TCC will not disengage
when brake is applied.

Harsh engagements, firm shift feel.
May flash TCIL.

Slight increase in EPC pressure.

Harsh engagements, firm shift feel,
abnormal shift schedule, abnormal
TCC operation or does not engage.

15

Technical Service Information

FORD 4R100

Diagnostic Trouble Code Chart

Diagnostic Code Description Symptom

P0713

TFT sensor circuit open, exceeds scale set for
temperature of minus 40°F .

TCC and stabilized shift schedule
may be enabled sooner after cold
start. May flash TCIL.

P0715

P0717
P0718
P0720

P0721
P0722
P0731

P0732

P0733

Insufficient input from TSS sensor .

TSS sensor signal intermittent.
TSS sensor signal noisy.
Insufficient input from OSS sensor .

OSS sensor signal noisy.
OSS sensor signal intermittent.

1-2 shift error because of SSA, SSB, or
internal transmission components.

2-3 shift error because of SSA, SSB, or
internal transmission components.

3-4 shift error because of SSA, SSB, or
internal transmission components.

Set DTC, Flash TCIL and Flash
MIL.

Set DTC, Flash TCIL.
Set DTC.
Set DTC, Flash TCIL and Flash

MIL.
Set DTC.
Set DTC, Flash TCIL.

Improper gear selection depending
on failure mode and transmission
range selector position. Refer to
shift solenoid operation chart.

Improper gear selection depending
on failure mode and transmission
range selector position. Refer to
shift solenoid operation chart.

Improper gear selection depending
on failure mode and transmission
range selector position. Refer to
shift solenoid operation chart.

16

P0741

P0743

P0750

P0755

The PCM picked up an excessive amount of
TCC slippage during normal operation.

TCC Solenoid circuit failure.

SSA circuit failur e.

SSB circuit failure.

Figure 19

AUTOMATIC TRANSMISSION SERVICE GROUP

TCC slippage/erratic or no torque
converter clutch operation. Flash
TCIL.
Short Circuit: Engine stalls in "D"
or "2" at idle with brake applied.
Open Circuit: TCC never engaged.

Improper gear selection depending
on failure mode and transmission
range selector position. Refer to
shift solenoid operation chart.

Improper gear selection depending
on failure mode and transmission
range selector position. Refer to
shift solenoid operation chart.

Technical Service Information

FORD 4R100

Diagnostic Trouble Code Chart

Diagnostic Code Description Symptom

P0781

P0782

P0783

P1100
P1101

P1111
P1120

1-2 shift error because of SSA, SSB, or
internal transmission components.

2-3 shift error because of SSA, SSB, or
internal transmission components.

3-4 shift error because of SSA, SSB, or
internal transmission components.

MAF sensor system fails to operate in a
normal manner, which may cause a
transmission concern.

System Pass. No Codes Detected.
Throttle Position Sensor voltage lower than

expected.

Improper gear selection depending
on failure mode and transmission
range selector position. Refer to
shift solenoid operation chart.

Improper gear selection depending
on failure mode and transmission
range selector position. Refer to
shift solenoid operation chart.

Improper gear selection depending
on failure mode and transmission
range selector position. Refer to
shift solenoid operation chart.

High EPC pressure. Firm shifts
and engagements. May flash TCIL.

Harsh engagements, firm shift feel,
abnormal shift schedule, abnormal
TCC operation or does not engage.

P1124

P1280

P1281

P1460
P1463
P1464

P1500

Throttle Position Sensor out of On-Board
Diagnostics range during KOEO test.

Injection Control Pressure (ICP) sensor
circuit failure (Diesel Engine), or out of range
low.

Injection Control Pressure (ICP) sensor
circuit failure (Diesel Engine), or out of range
high.

A/C switch error .

Insufficient or intermittent vehicle speed
input from VSS/ABS.

TP sensor (Gas Engines) not at idle
position during KOEO test.

May result in firm shifts.

May result in firm shifts.

Failed On: EPC pressure slightly
low with A/C off.
Failed Off: EPC pressure slightly
low with A/C on.

Harsh engagements, firm shift feel,
abnormal shift pattern, unexpected
downshifts may occur at closed
throttle, abnormal TCC operation or
engages only at WOT. May flash
TCIL.

Figure 20

AUTOMATIC TRANSMISSION SERVICE GROUP

17

Technical Service Information

FORD 4R100

Diagnostic Trouble Code Chart

Diagnostic Code Description Symptom

P1702

Digital Transmission Range (DTR) sensor
signal intermittent.

Erratic harsh shift engagements.

P1703

P1704

P1705

P1711

P1713
P1714

P1715

(BPP) Brake Pedal Position switch not
actuated during KOER test.

Digital Transmission Range (DTR) sensor
misaligned or failed electronically .

Digital T ransmission Range (DTR) sensor not
run in park or neutral during On-Board
Diagnostics KOEO or KOER tests.

Transmission not at operating temperature
during On-Board Diagnostics.

No change in TFT sensor - Low range.
SSA mechanical failure detected.

SSB mechanical failure detected.

Failed on or not connected, TCC
will not engage at less than one­third throttle opening.

Increase in EPC pressure.

Rerun On-Board Diagnostics.

Warm vehicle to normal operating
temperature and rerun On-Board
Diagnostics.

May flash TCIL.
Improper gear selection depending

on failure mode and transmission
range selector position. Refer to
shift solenoid operation chart.

Improper gear selection depending
on failure mode and transmission
range selector position. Refer to
shift solenoid operation chart.

P1718
P1728

P1729
P1740
P1744

P1746

P1747

No change in TFT sensor - High range.

Excessive amount of transmission slippage
has been detected.

4X4 Low switch circuit failure.
TCC solenoid mechanical failure detected.
The PCM picked up an excessive amount of

TCC slippage during normal operation.

Failure of the EPC control pressure driver
located inside the PCM.

EPC shorted circuit failure, or PCM.

May flash TCIL.
Transmission slippage, erratic or no

TCC operation. May flash TCIL.

Early or delayed shift schedule.
Harsh shift, may flash TCIL.
TCC slippage/erratic or no torque

converter clutch operation. Flash
TCIL.

Open circuit causes maximum EPC
pressure, harsh engagements and
shifts. May flash TCIL.

Shorted circuit causes minimum
EPC pressure, limits engine torque
with partial fuel shut off and heavy
misfire. Flashing TCIL.

18

Figure 21

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

FORD 4R100

Diagnostic Trouble Code Chart

Diagnostic Code Description Symptom

P1754

P1760

P1780

P1781
P1783

CCS circuit failure.

EPC signal intermittent short.

TCS not cycled during the On-Board
Diagnostics or the circuit is open or shorted.

4X4 Low switch circuit failure.
Transmission Fluid Temperature has

exceeded 270°F .

Failed Off: No third gear engine
braking in O.D. cancel.
Failed On: Third gear engine
braking in O.D. range. Coast clutch
may be damaged causing eventual
failure.

Short circuit causes minimum EPC
pressure.

No overdrive cancel when switch is
cycled.

Early or delayed shift schedule.
Slight increase in EPC pressure.

May flash TCIL.

Figure 22

AUTOMATIC TRANSMISSION SERVICE GROUP

19

Technical Service Information

Shift Solenoid Application Chart

Selector Lever

Range

P/R/N 1

D
D
D
D

D

Cancel

MANUAL 1
MANUAL 1

Controlled by PCM

*

Commanded

Gear

1
2
3
4

First Through 3rd Gear Only, SSA, SSB, TCC, Same as Overdrive, CCS Always On.

2MANUAL 2
2
1

Shift

Solenoid "A"

ON
ON

ON
OFF
OFF

OFF

ON

Shift

Solenoid "B"

OFF
OFF

ON
ON

OFF

OFF
OFF OFF

TCC

Solenoid

* *
* *
* *
* *
*

***

OFF

Coast Clutch

Solenoid

*

ON
ON
ON

SHIFT SOLENOID TROUBLE CHART GUIDE

SHIFT SOLENOID "A" ALWAYS OFF

Selector Lever Position

PCM Gear

Commanded

1st

2nd

3rd
4th

SHIFT SOLENOID "A" ALWAYS ON

PCM Gear

Commanded

1st

2nd

3rd

D

Actual Gear Obtained

4
3
3
4

Selector Lever Position

D

Actual Gear Obtained

1
2
2

2 1

2
2
2
2 2

2 1

2
2
2

SHIFT SOLENOID "B" ALWAYS OFF

Selector Lever Position

PCM Gear

Commanded

1
2
2

1
1
1

1st

2nd

3rd
4th

SHIFT SOLENOID "B" ALWAYS ON

PCM Gear

Commanded

1st

2nd

3rd

D

Actual Gear Obtained

1 1

4
4

Selector Lever Position

D

Actual Gear Obtained

2 2
2
3

2 1

2
2
2
2 2

2 1

2
2

11
2

1
1
2

20

4th

1

2

1

Figure 23

4th

3

2

2

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

LINE PRESSURE TEST

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

FordFord

RFF81P-7006-BA

98

Fo

rd

C

A

-

P

W4

X

B

-

L

J

R

1

6

3

4

0

0

7

1

C

9

-

BD

LINE PRESSURE SPECIFICATION CHART

Gear

P, N

R

OD, M2

M1

Idle

50-65 psi

70-100 psi

50-65 psi

70-115 psi

Stall

220-240 psi
136-156 psi
175-210 psi

Figure 24

LINE PRESSURE TEST

NOTE: Perform the line pressure test before
performing the "Stall" test. If the line pressure is
low at "Idle", DO NOT perform the "Stall" test or
further transmission damage will occur.
Do Not Maintain Wide Open Throttle in any gear
range for more than "5 Seconds" or transmission
damage may occur.

NOTE: If equipped, turn "Off" the PTO unit to
ensure proper test results.

NOTE: On vehicles equipped with PTO units,
access to the line pressure port may require that you
remove the PTO unit depending on the type of unit
installed. If required, remove the PTO unit and
install PTO cover and gasket "Before" doing the
line pressure test.

Copyright © 2003 ATSG

1. Install a 300 psi line pressure gauge to the line
pressure tap, as shown in Figure 24.

2. Start the engine and check line pressure in all
ranges at "Idle". Refer to the chart shown in
Figure 24 to determine if they are within the
specifications.

3. If the line pressures are within the specifications
at "Idle", now you can perform the "Stall" test
to determine if specifications are okay there.

4. Once again, refer to the chart in Figure 24, to
determine proper specifications at "Stall".

AUTOMATIC TRANSMISSION SERVICE GROUP

21

Technical Service Information

FORD 4R100

"NON-PTO" AND "PTO"

HYDRAULIC DIFFERENCES

CHANGE:

REASON:

PAR TS AFFECTED:

Begining at the start of production for 1999 models, Ford Motor Company made available a "Power
Take Off" option for some F250, F350, F450 and F550 Super Duty Trucks, equipped with 5.4L,

6.8L and 7.3L engines.

The "PTO" option addition, to the 4R100, required many changes to the transmission to make the
"PTO" function. The "PTO" window, added to the case, the "PTO" drive gear and other cosmetic
changes were covered on Page 6 in this manual. Hydraulic changes also had to be made to make
the coast clutch operate in ranges other than the Drive ranges (See Figure 35).

(1)

TRANSMISSION CASE: The transmission case was changed to accommodate the "PTO"
window, as shown in this manual. All 4R100 Cases, "NON-PTO"and "PTO,"also had a "Dam"
added to seperate "Rear Lube" and to incorporate "Central Lube"as shown in Figure 25.

(2)

VALVE BODY TO CASE SPACER PLATE: The Valve Body to Case Spacer plate on the "PTO"
versions had a hole added to supply the 3-4 Shift V alve with Line Pressure, as shown in Figure 27. A
hole was also added to the Spacer Plate on "NON-PTO" and "PTO" versions to connect "Solenoid
Regulator Valve" oil to supply "Central Lubrication." Refer to Figures 26 and 27 for identification
of "NON-PTO"and "PTO" Valve Body T o Case Spacer Plates.

(3)

MAIN VALVE BODY: A passage was added on the "Upper Side" of the Main Valve Body on
"PTO" versions, as shown in Figure 29, to supply Line Pressure to the 3-4 Shift Valve. A passage
was also added, on the "Lower Side" of the Main Valve Body, to connect the 3-4 Shift Valve (Coast
Clutch Circuit) to an exhaust as shown in Figure 31. The spring side of the 3-4 Shift Valve was also
seperated from the Low/Reverse circuit as shown in Figure 31. Refer to Figures 28 thru 31 for
identification of "NON-PTO" and "PTO" Main Valvebody's.

(4)

LOWER VALVE BODY: The Lower Valve Body has a passage added, as shown in Figure 33, to
connect to the "new"exhaust passage in the Main Valve Body. Refer to Figures 32 and 33, for
identification of "NON-PTO" and "PTO" Lower Valvebody's.

(5)

LOWER VAL VE BODY SPACER PLATE: The Lower Valve Body Spacer Plate had a hole added
to connect the "new" exhaust passage in the Main Valve Body to the "new" exhaust passage in the
Lower Valve body a shown in Figure 34. Refer to Figure 34 for "NON-PTO" and "PTO" Lower
V alve Body Spacer Plate identification.

INTERCHANGEABILITY :

None of the parts listed above will interchange between "NON-PTO" and "PTO" versions.

SERVICE INFORMATION:

Valve Body To Case Spacer Plate (Non-PTO) .................. ................................F81Z-7A008-DA

Valve Body To Case Spacer Plate (PTO) ...........................................................F81Z-7A008-BA

22

Copyright © 2003 ATSG

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

4R100 CASE ASSEMBLY

"NON-PTO" AND "PTO" MODELS

CENTRAL LUBE

REAR LUBE

ADDED OIL

DAM

Figure 25

AUTOMATIC TRANSMISSION SERVICE GROUP

Copyright © 2003 ATSG

23

Technical Service Information

4R100 MAIN SPACER PLATE

"NON-PTO" MODELS ONLY

1212

CENTRAL LUBE

ORIFICE

9797

24

I.D.- 1 DOVE TAIL

PART NUMBER
F81Z-7A008-DA

AUTOMATIC TRANSMISSION SERVICE GROUP

F81P-DAF81P-DA

Copyright © 2003 ATSG

Figure 26

Technical Service Information

4R100 MAIN SPACER PLATE

"PTO" MODELS ONLY

66

CENTRAL LUBE

ORIFICE

9898

ADDED MAIN LINE PRESSURE HOLE

FROM PRESSURE REGULATOR VALVE

I.D.- 2 DOVE TAILS

PART NUMBER

F81Z-7A008-BA

AUTOMATIC TRANSMISSION SERVICE GROUP

F81P-BAF81P-BA

Copyright © 2003 ATSG

Figure 27

25

Technical Service Information

"UPPER SIDE" 4R100 MAIN VALVE BODY

"NON-PTO" MODELS ONLY

26

Copyright © 2003 ATSG

Figure 28

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

"UPPER SIDE" 4R100 MAIN VALVE BODY

"PTO" MODELS ONLY

PASSAGE ADDED TO

FEED LINE PRESSURE TO

THE 3-4 SHIFT VALVE

Figure 29

AUTOMATIC TRANSMISSION SERVICE GROUP

Copyright © 2003 ATSG

27

Technical Service Information

"LOWER SIDE" 4R100 MAIN VALVE BODY

"NON-PTO" MODELS ONLY

7A092-AB

7A092-AB

RFF61P-

RFF61P-

FordFord

Du PageDu Page

66

0932809328

I.D.-ROUGH FORGING

NUMBER OF "RF-F6" WHICH

INDICATES "96"

28

LOW/REVERSE

CLUTCH

Copyright © 2003 ATSG

Figure 30

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

"LOWER SIDE" 4R100 MAIN VALVE BODY

"PTO" MODELS ONLY

PP

7A092-AA

7A092-AA

RFF81P-

RFF81P-

FordFord

Du PageDu Page

11

1953819538

I.D.-ROUGH FORGING

NUMBER OF "RF-F8" WHICH

INDICATES "98"

PASSAGE ADDED
LEADING TO THE
EXHAUST IN THE

LOWER VALVE BODY

LOW/REVERSE

PASSAGE RE-MOVED

FROM SPRING SIDE

OF 3-4 SHIFT VALVE

LOW/REVERSE

CLUTCH

AUTOMATIC TRANSMISSION SERVICE GROUP

Copyright © 2003 ATSG

Figure 31

29

Technical Service Information

4R100 LOWER VALVE BODY

"NON-PTO" MODELS ONLY

FordFord

AA

I.D.-ROUGH FORGING

NUMBER OF "RF-F6" WHICH

INDICATES "96"

RFF61P-7A101RFF61P-7A101

Du PageDu Page

55

0982809828

30

Copyright © 2003 ATSG

Figure 32

AUTOMATIC TRANSMISSION SERVICE GROUP